Modular, structural, element, space frame or truss

ABSTRACT

A prefabricated, modular, structural element, space frame or truss assembled from a series of “Z”-shaped modules comprised of three (3) or five (5) structural members, connected at the upper and lower chords. Verticals, end posts or multi-member end sections can be added if required for structural integrity or to improve utility. The individual elements, space frames, or trusses assembled from the modules can be used individually or combined in a variety of configurations to create permanent, temporary or emergency structures on any scale.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is a prefabricated, portable, structural module, which canbe used singly or connected in series to form a structural element, aspace frame or a truss. The invention primarily pertains to patentclassification 52, as a static structural element, but may also pertainto classification 14 with respect to portable, trusses for bridges.Examples of similar Classification 52 devices appear in U.S. Pat. Nos.5,003,748 and 6,205,736. Classification 14 previous patents includetemporary bridging such as UK Patent 553,374, U.S. pat. Nos. 4,912,795and 5,065,467.

2. Background Art

The invention differs from previous patents in that simple, 3-member or5-member, prefabricated, modules are used exclusively to assemble astructural element, space frame or truss. The invention is easilyfabricated, portable and allows flexibility in the scale of theinvention, which in turn provides the invention with nearly limitlessutility as a structural element. Design variables of the invention are:member size, strength of materials and ultimate configuration. Anyappropriate, structural section and material can be used to fabricatemodules. Configurations can include combinations similar to priorinventions such as the “Bailey Bridge” system, and others, in whichtrusses are connected together to form multiple-truss and multiple-storystructures.

Because the invention can be designed and configured as a space frame ora truss, limitations associated with member eccentricities imposed byideal truss design are eliminated. Although frame analysis is morecomplex, using computer assisted design methods readily facilitatesanalysis and design. Modules consist of three (3) or five (5) structuralmembers fabricated into a basic “Z” shape. A 3-member module is modifiedto a 5-member module by the addition of vertical members at each end. Amodule can be used singly or further assembled by connecting a series ofmodules in a pattern or repeating orientation into a structural element.A space frame or truss can be assembled from a structural element by theaddition of end units consisting of single end posts or special endscomprised of more than one member. Module-to-module connections arechord splices with the details dependent on load capacity and deflectionrequirements of the structure. Modules can be combined duringfabrication by using continuous chord members thereby requiring fewerchord connections when erected.

SUMMARY OF INVENTION

The main object of the invention is to provide a simple, prefabricated,portable, structural module, which is assembled into a structuralelement, a structural frame or a truss. The invention's designparameters can be varied to create small or large structural elementscapable of long, single spans, but still allow simple fabrication,transportation and erection. The basic building block is a structuralmodule comprised of three (3) or five (5) members: Two (2), parallel,chord members are connected together by a diagonal member to form a3-member module in the shape of a “Z”. Addition of two (2), verticalmembers at the ends of the parallel chord members form a 5-membermodule. Single end posts or special end sections consisting of more thanone member are added at the ends of a structural element as needed toform a complete space frame or truss.

The second object of the invention is to create a portable structuralframe or truss with a wide range of utility for permanent, temporary oremergency structures. Load capacities and span lengths for the inventioncan be designed for individual applications or can be determined by loadcapacity charts for standard module sizes. Span length and load capacityrequirements determine the scale of the invention. Frames or trussesassembled from large modules can be designed for clear spans in excessof 300 feet capable of supporting loads in excess of 50 tons. Themodules are prefabricated from any material with appropriate structuralproperties.

Another object of the invention is to reduce structural fabrication,transportation and erection costs. The 3-member modules of thisinvention require two (2) permanent connections, representing a usefulsimplicity of fabrication. Prefabricating a series of combined modulesusing continuous chord members increases the invention's efficiency bydecreasing the number of chord connections required during erection andproviding a control on length and weight for purposes of transportationand erection.

In summary, the invention is a simple, structural module of variablesize, which is easily fabricated, transported and erected. The modulesare prefabricated, and used as structural elements, space frames, ortrusses. High load capacities and long, clear spans are possible due tothe invention's inherent flexibility of design, which also allows theinvention a range of utility for use in temporary, permanent oremergency structures on any scale required.

DESCRIPTION OF DRAWINGS

FIG. 1A is an elevation view of a structural element illustrating largeeccentricities at member connection points, which require space frameanalysis.

FIG. 1B is an elevation view of a structural element illustrating smallor no eccentricities at member connection points, which allow idealtruss analysis.

FIG. 1C is an isometric view of a single, 3-member, space frame modulewith individual members labeled.

FIG. 1D is an isometric view of a single, 3-member, truss module withindividual members labeled.

FIG. 2A is an isometric view of a single, 5-member, space frame module,illustrating addition of vertical members to the ends of a 3-member,module to form a 5-member, space frame module.

FIG. 2B is an isometric view of a single, 5-member, truss module,illustrating addition of vertical members to the ends of a 3-member,module to form a 5-member, truss module.

FIG. 3A is an isometric view of a structural element comprised of two(2), 3-member, space frame modules connected in a mirror imageorientation.

FIG. 3B is an isometric view of a structural element comprised two (2),3-member, truss modules connected in a mirror image orientation.

FIG. 4A is an isometric view of a structural element (or frame)comprised two (2), 5-member. Space frame modules connected in a mirrorimage orientation.

FIG. 4B is an isometric view of a structural element (or truss)comprised two (2), 5-member, truss modules connected in a mirror imageorientation.

FIG. 4C is an isometric view of a space frame comprised of two (2),3-member, space frame modules connected in a mirror image orientationwith multi-member end sections.

FIG. 4D is an isometric view of a space frame comprised two (2),3-member, truss modules connected in a mirror image orientation withmulti-member end sections added to create a space frame.

FIG. 5A is an isometric view of a space frame comprised of four (4),3-member, space frame modules connected in a mirror image orientationwith single member end sections.

FIG. 5B is an isometric view of a Warren truss comprised of four (4),3-member, truss modules connected in a mirror image orientation withsingle member end sections.

FIG. 6A is an isometric view of a structural space frame assembled usingfour (4), 5-member, space frame modules connected in a mirror imageorientation.

FIG. 6B is an isometric view of a Warren truss with verticals assembledusing four (4), 5-member, truss modules connected in a mirror imageorientation.

FIG. 7A is an isometric view of two (2) structural, space framesconsisting of four (4), 3-member, space frame modules each, in turnconnected together to form a single story, double frame configuration.

FIG. 7B is an isometric view of four (4) space frames consisting of four(4), 3-member, space frame modules each, with single member endsections. The frames are then connected together horizontally andvertically in a double frame—double story arrangement.

FIG. 7C is an isometric view of a space frame comprised of four (4),3-member, space frame modules in a symmetric pattern mirrored at halfspan.

FIG. 7D is an isometric view of a space frame assembled from four (4),3-member, space frame modules connected in series illustrating anothervariation.

FIG. 8 is an isometric view of a space frame connected to large,structural, chord members. The figure illustrates using the frame as aweb for a large, built-up member, but also illustrates how a frame andanother beam can be used to support an existing beam.

FIG. 9 is an isometric view of 3-member, structural elements used asbracing between two (2) columns.

FIG. 10 is an isometric view of tubular, 3-member truss members used asstructural elements between the columns of a tubular tower structure.

FIG. 11 is an isometric view of 3-member, truss and frame modulesprefabricated with continuous chord members to reduce the number offield chord connections and create a convenient length fortransportation and erection.

FIG. 12 is an isometric view of 5-member truss modules used to assemblea rectangular tower structure and a similar rectangular tower next tofirst assembled from 3-member modules used as structural elementsattached to continuous columns.

FIG. 13 is an elevation view of 5-member frame modules assembled to forman arch.

DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1A demonstrates the case for which space frame design is required.Large eccentricities between projected points of intersection (POI) ofdiagonal member centerlines CL and the centerlines CL of chord membersare large and do not coincide. Modules A, B, C and D are typical, spaceframe modules. The point of intersection (POI) of projected centerlinesCL of diagonal members 101 in modules A and B and modules C and D lieabove the centerlines CL of upper chord members 100. The point ofintersection (POI) of the projected centerlines CL of diagonal members101 in modules B and C lie below the centerlines CL of lower chordmembers 102. Eccentricities in space frame modules are created due tothe ends of chord members 100 and 102 extending past the ends ofdiagonal members 101.

FIG. 1B demonstrates the case for which ideal truss design isacceptable. Generally speaking, eccentricities are eliminated and pointsof intersection (POI) of member centerlines CL coincide or eccentricdistances are negligible. Ideal truss design requires a combination ofconnected triangles. Modules AA, BB, CC and DD are typical trussmodules. The point of intersection (POI) of projected centerlines CL ofdiagonal members 11 in modules AA and BB and modules CC and DD intersectwith the centerlines CL of upper chord members 10. The point ofintersection (POI) of projected centerlines CL of diagonal members 11 inmodules BB and CC intersect with the centerlines CL of lower chordmembers 12. Eccentricities in truss modules are eliminated due to theends of chord members 10 and 12 ending exactly at the ends of diagonalmembers 11. Very small eccentricities are acceptable.

FIG. 1C is a 3-member, space frame module illustrating upper chord 100,diagonal 101 and lower chord 102. Chord members 100 and 102 in the spaceframe configuration extend well past the ends of diagonal member 101.

FIG. 1D is a 3-member, truss module illustrating upper chord 10,diagonal 11 and lower chord 12. The ends of chord members 10 and 12 donot extend past the ends of diagonal 11 in this configuration.

FIG. 2A is a 5-member, space frame module. Upper chord 100, diagonal 101and lower chord 102 are converted from a 3-member module as shown inFIG. 1C to a 5-member module by the addition of vertical members 103 ateach end of the chord sections 100 and 102.

FIG. 2B is a 5-member, truss module. Upper chord 10, diagonal 11 andlower chord 12 are converted from a 3-member module as shown in FIG. 1Dto a 5-member module by the addition of vertical members 13 at each endof the chord sections 10 and 12.

FIG. 3A shows two (2), 3-member, space frame modules A and B, connectedin a mirror image orientation. Both modules are identical, but module Bis rotated to a mirror image orientation. Upper chord module connections100, module A to 100, module B and lower chord connections 102, module Ato 102, module B are designed as chord splices.

FIG. 3B shows two (2), 3-member, truss modules AA and BB, connected in amirror image orientation. Both modules are identical, but module BB isrotated to a mirror image orientation. Upper chords connections 10,module AA to 10, module BB and lower chord connections 12, module AA to12, module BB are designed as chord splices.

FIG. 4A shows two (2), 5-member, space frame modules; A and B connectedin a mirror image orientation. Addition of vertical members 103 convertsa 3-member module consisting of members 100, 101 and 102 to a 5-membermodule. To assemble a complete space frame, modules are added in similarfashion until a full span length is assembled. No additional endsections are required for 5-member, space frame modules.

FIG. 4B shows two (2), 5-member, truss modules; AA and BB connected in amirror image orientation. Addition of vertical members 13 converts a3-member module consisting of members 10, 11 and 12 to a 5-membermodule. To assemble a complete truss, modules are added in similarfashion until a full span length is assembled. No additional endsections are required for 5-member, truss modules.

FIG. 4C illustrates two (2), 3-member, space frame modules; A and Bconnected in a mirror image orientation with multi-member end sections;C consisting of members 104, 105 and 106 added to complete a frame. Thiscase demonstrates the use of special end sections C comprised of severalstructural members. The special end sections C are used in lieu of asimple end post configuration. Splices to upper chords 100 and lowerchords 102 of Modules A and B connect the end sections C.

FIG. 4D illustrates a space frame configuration using two (2), 3-member,truss modules; AA and BB connected in a mirror image orientation, madeinto a completed space frame element by using multi-member end sectionmodules CC comprised of members 14, 15 and 16 at the ends of themodules. The multi-member end sections CC used in this case do notmaintain a series of connected triangles necessary for ideal trussanalysis and therefore the completed element as a whole must be designedas a space frame and not a truss. Splices to upper chords 10 and lowerchords 12 of Modules AA and BB connect the end sections CC.

FIG. 5A and FIG. 5B show four (4), 3-member, modules; A, B, C, D (spaceframe modules) and AA, BB, CC, DD (truss modules) in completed spaceframe and truss configurations, respectively. These figures demonstratethe use of simple end posts 103 and 13. All module members andconnections are as previously identified. This configuration if rotated90 degrees can be used as a column or portion of a column if used incombination such as a rectangular tower as illustrated in FIG. 12 below.

FIG. 6A and FIG. 6B show four (4), 5-member, modules: A, B, C, D (spaceframe modules) and AA, BB, CC, DD (truss modules) in completed spaceframe and truss configurations, respectively. No additional end sectionsare necessary to complete the frame or truss for 5-member modules due toverticals 103 and 13 at the ends of each module. All module members andconnections are as previously identified. This configuration can also beused to form columns when rotated 90 degrees vertically.

FIG. 7A depicts a multiple element space frame configuration (double)with 2 complete space frames of four (4), 3-member, modules each. Endposts 103 are used at the end of each span to complete each frame.Individual modules; A, B, C, D, comprise one space frame and modules; E,F, G, H form another. All module members and connections are aspreviously identified. In addition to chord splices within each frame,the frames are connected to each other top chord to top chord and bottomchord to bottom chord in a horizontal plane to realize full,synergistic, load capacity of the combined frames.

FIG. 7B is a double frame element as in FIG. 7A, further assembled intoa double frame-double story element consisting of four (4), complete,space frames comprised of four (4), 3-member, space frame modules eachwith end posts 103 at ends of the connected modules to compete eachspace frame element. Individual modules in the bottom pair of frames arelabeled A through D on the inboard frame and E through H on the outboardframe. Individual modules in the top pair of frames are labeled Ithrough L inboard and M through P outboard. In addition to chordsplices, the frames are connected to each other side-to-side in ahorizontal plane as in FIG. 7A and top chord-to-bottom chord in avertical plane so that full synergistic load capacity of the combinedframes is realized. Similar configurations as those shown in FIG. 7A and7B have been used in the “Bailey Bridge” and other panel truss bridgingsystems since World War II.

FIG. 7C illustrates a variation in module orientation. Instead of everymodule being connected as a mirror image of the previous module, modulesA and B are placed identically end-to-end for one half of a span. Theother half of the span comprised of modules C and D is similar, but themodule orientation is opposite in direction. All members within themodules are as previously identified. End Posts 103 are used at the endsof the span to complete the structural element.

FIG. 7D depicts another variation in module orientation. All modules A,B, C, and D are oriented in the same direction. All members within themodules are as previously identified. End Posts 103 are used at the endsof the span to complete the structural element.

FIG. 8 illustrates a modular space frame used in conjunction with other,non-modular, structural member(s) to create a new, structural element orto brace an existing structural element in place. Chord beams 200 and202 are connected to top and bottom of modular space frame chord members100 and 102, respectively to form a new, structural member with a largeflexural capacity. If member 200 is considered an existing structuralbeam in place, the invention consisting of members 100, 101, 102 and 103combined with (or without) structural member 202 depict the invention'sutility as a strengthening or bracing element as may be required in apermanent or temporary repair, or an emergency structural situation.

FIG. 9 illustrates frame modules used as bracing for columns 200. Allframe members are as previously identified.

FIG. 10 shows tubular, 3-member truss modules members 10, 11 and 12 usedas bracing for a tubular column arrangement to create a tower.

FIG. 11 illustrates the use of continuous top chord and bottom chords.Section A illustrates a series of truss modules with continuous uppercord 10 and lower chord 12 of equal length. Diagonals 11 are attached ina mirror image orientation to form an entire section of truss modules.This configuration maintains the module concept, as the chords are equalin length. Section B illustrates the continuous chord configuration fora frame section with upper chord 100 and lower chord 102 again the samelength. Diagonals are shown in a mirror image orientation. Thecontinuous chord, prefabricated section can be used to eliminate some ofthe chord splices required where a long series of individual moduleswould otherwise be used. The continuous chord length can be adjusted toachieve the most economical length for transportation and erectionpurposes. The small number of connections demonstrates the invention'seconomy in fabrication.

FIG. 12 demonstrates the use of modules in two (2) ways. Tower Arepresents a truss comprised of 5-member truss modules rotated 90degrees to create the sides of the tower. Upper chord 10, diagonal 11and lower chord 12 are made into 5-member modules using end posts 13.Tower B illustrates the use of 3-member truss modules as structuralelements in combination with continuous columns to create a towersimilar to Tower A. Upper chord 10 diagonal 11 and lower chord 12represent 3-member modules. Interior chord members are shown as singlemembers instead of doubled in this figure for clarity. The columns COLare shown as continuous columns. The figure demonstrates the flexibilityof the invention by allowing the most economical and practicalcombinations for the intended purpose to be used. The 5-memberarrangement may be preferable for transportation and erection while the3-member arrangement may be preferable if continuous columns are moreeconomical or if the columns were existing columns.

FIG. 13 illustrates the use of 5-member frame modules to create andarched, structural element or frame. All of the members are aspreviously identified, upper chord members 100, diagonals 101, lowerchord members 102, and end or vertical members 103. The invention allowsthe use of tapered verticals or mitered chord ends to create camber oran arched element as seen here.

1. The invention claimed is a 3-member, structural, space frame module,comprised of two (2), parallel, structural, chord members joinedtogether by a third structural member connected in a diagonalorientation to form a 3-member, space frame module, in which ends ofchord members extend past the ends of the diagonal member.
 2. Theinvention claimed is a 3-member, structural, truss module, comprised oftwo (2), parallel, structural chord members joined together by a thirdstructural member connected in a diagonal orientation to form a3-member, truss module, in which chord members end at and intersect withthe ends of said diagonal member, but do not extend past the ends of thediagonal member.
 3. The invention claimed is a 3-member, space framemodule or 3-member, truss module according to claim 1 or claim 2,further comprising two (2), additional, vertical, structural, membersconnected from the upper chord to the lower chord, at each end of theparallel chord members of said 3-member, space frame or truss modulethereby forming a 5-member, space frame module or a 5-member, trussmodule.
 4. The invention claimed is a structural module according toclaims 1, 2 or 3 as further comprising modular, structural elements,space frames or trusses, configured as; an individual module,combinations of modules connected in any orientation or combinations oforientations, or as combinations of said modules configured andassembled with other, new or existing, structural, members in theforming of said structural elements, space frames or trusses.
 5. Theinvention claimed is a structural module according to claims 1, 2, 3 or4 as fabricated with continuous upper chord and lower chord membersbeing of the approximate same length or as altered to form a structuralarch or cambered elements, entailing any number of truss or framemodules in combination to form a one-piece, structural module extendedin length and with fewer chord connections.
 6. The invention claimed isa modular structural element, space frame or truss in accordance withclaims 4 or 5 wherein the invention is further comprised of like orsimilar modular; elements, space frames or trusses by connecting upperchord to upper chord and lower chord to lower chord in a horizontalplane, or connecting upper chord to lower chord in a vertical plane thusassembling a plurality of said elements, space frames or trusses.
 7. Theinvention claimed is a modular structural element, space frame or trussin accordance with claims 4, 5 or 6 as further comprised of additionalstructural chord members connected to the bottoms of original lowerchord members, the tops of original upper chord members, or similarlyconnected to both original upper and lower chord members of saidstructural element, space frame, or truss.